U.S. patent application number 11/857876 was filed with the patent office on 2008-03-20 for simulated seafood compositions comprising structured plant protein products and fatty acids.
This patent application is currently assigned to Solae, LLC. Invention is credited to Andreas G. Altemueller.
Application Number | 20080069927 11/857876 |
Document ID | / |
Family ID | 38974054 |
Filed Date | 2008-03-20 |
United States Patent
Application |
20080069927 |
Kind Code |
A1 |
Altemueller; Andreas G. |
March 20, 2008 |
SIMULATED SEAFOOD COMPOSITIONS COMPRISING STRUCTURED PLANT PROTEIN
PRODUCTS AND FATTY ACIDS
Abstract
The invention provides simulated seafood compositions containing
a structured plant protein product and fatty acid such that the
simulated seafood composition of the invention has the flavor and
smell of seafood meat and contains levels of omega-3 fatty acids
comparable to the levels found in seafood rich in omega-3 fatty
acids.
Inventors: |
Altemueller; Andreas G.;
(Webster Groves, MO) |
Correspondence
Address: |
SOLAE, LLC
P. O. BOX 88940
ST. LOUIS
MO
63188
US
|
Assignee: |
Solae, LLC
St. Louis
MO
|
Family ID: |
38974054 |
Appl. No.: |
11/857876 |
Filed: |
September 19, 2007 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
60826360 |
Sep 20, 2006 |
|
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|
Current U.S.
Class: |
426/104 |
Current CPC
Class: |
A23L 33/12 20160801;
A23J 3/16 20130101; A23L 17/00 20160801; A23P 30/20 20160801; A23L
11/05 20160801; A23J 3/225 20130101 |
Class at
Publication: |
426/104 |
International
Class: |
A23L 1/325 20060101
A23L001/325 |
Claims
1. A simulated seafood composition, the seafood composition
comprising: (a) a structured plant protein product; and (b) a fatty
acid.
2. The simulated seafood composition of claim 1, wherein the
structured plant protein product is produced by extrusion.
3. The simulated seafood composition of claim 2, wherein the
structured plant protein comprises protein fibers that are
substantially aligned.
4. The simulated seafood composition of claim 3, wherein the
structured plant protein is derived from a plant selected from the
group consisting of legumes, soybeans, wheat, oats, corn, peas,
canola, sunflowers, rice, amaranth, lupin, rape, and mixtures
thereof.
5. The simulated seafood composition of claim 4, wherein the
structured plant protein comprises soy protein and wheat
protein.
6. The simulated seafood composition of claim 5, wherein the
structured plant protein has an average shear strength of at least
1400 grams and an average shred characterization of at least 10% by
weight of large pieces.
7. The simulated seafood composition of claim 1, wherein the fatty
acid imparts the flavor or smell of seafood meat.
8. The simulated seafood composition of claim 7, wherein the fatty
acid is selected from the group consisting of polyunsaturated fatty
acid, omega-3 fatty acid, omega-6 fatty acid, and omega-9 fatty
acid.
9. The simulated seafood composition of claim 6, further comprising
a seafood meat selected from the group consisting of fish meat,
shellfish meat, crustacean meat, mollusk meat, scallop meat, squid
meat, octopus meat, and mixtures there of.
10. The simulated seafood composition of claim 9, wherein the fish
meat is selected from the group consisting of tuna, salmon, trout,
catfish, cod, flounder, sea bass, orange roughy, walleye, and
mixtures thereof.
11. The simulated seafood composition of claim 10, wherein the
concentration of structured plant protein present in the seafood
composition ranges from about 1% to about 99% by weight and the
concentration of seafood meat present in the seafood composition
ranges from about 10% to about 75% by weight.
12. The simulated seafood composition of claim 9, wherein the
structured plant protein comprises soy protein and wheat protein;
the fish meat comprises tuna; and wherein the seafood composition
substantially has the flavor and smell of tuna meat.
13. The simulated seafood composition of claim 9, wherein the
structured plant protein comprises soy protein and wheat protein,
the fish meat comprises salmon; and wherein the seafood composition
substantially has the flavor and smell of salmon meat.
14. The simulated seafood composition of claim 1, further
comprising seafood oil, seafood extract, or seafood broth.
15. A simulated seafood composition, the seafood composition
comprising: (a) a structured plant protein product, wherein the
structured plant protein product comprises protein fibers that are
substantially aligned; (b) an omega-3 fatty acid; and (c) an
appropriate colorant.
16. The simulated seafood composition of claim 15, further
comprising seafood meat.
17. The simulated seafood composition of claim 16, wherein the
structured plant protein product has an average shear strength of
at least 1400 grams and an average shred characterization of at
least 10% by weight of large pieces.
18. A simulated seafood composition, the seafood composition
comprising: (a) a structured soy protein product, wherein the
structured soy product comprises protein fibers that are
substantially aligned; (b) an omega-3 fatty acid; and (c) an
appropriate colorant.
19. The simulated seafood composition of claim 18, further
comprising seafood meat.
20. The simulated seafood composition of claim 19, wherein the
seafood meat is tuna meat or salmon meat.
Description
FIELD OF THE INVENTION
[0001] The present invention provides simulated seafood
compositions comprising structured plant protein products and fatty
acids.
BACKGROUND OF THE INVENTION
[0002] The American Heart Association recommends that healthy
adults eat at least two servings of seafood per week, and in
particular, seafood rich in omega-3 fatty acids. Seafood with high
levels of omega-3 fatty acids include anchovies, catfish, clams,
cod, herring, lake trout, mackerel, salmon, sardines, shrimp, and
tuna. Consumption of seafood rich in omega-3 fatty acids is
associated with decreased risk of heart diseases, reduction of
cholesterol levels, regulation of high blood pressure, and
prevention of arteriosclerosis. Increased demand for seafood has
reduced the wild populations, which has lead to increased prices.
Thus, attempts have been made to develop acceptable seafood-like
products from relatively inexpensive plant protein sources.
[0003] Food scientists have devoted much time developing methods
for preparing acceptable meat-like food products, such as beef,
pork, poultry, fish, and shellfish analogs, from a wide variety of
plant proteins. Soy protein has been utilized as a protein source
because of its relative abundance, reasonably low cost, and
presence of nutritionally advantageous components. Extrusion
processes typically prepare meat analogs. The dry blend is
processed to form a fibrous material. To date, most extruded high
protein meat analogs have not met public acceptance because they
lack the texture and "mouth feel" of meat. Rather, they are
characterized as spongy and chewy, largely due to the random,
twisted nature of the protein fibers that are formed. Most are used
as extenders for ground, hamburger-type meats.
[0004] There is a still an unmet need for a structured plant
protein product that simulates the fibrous structure of animal and
seafood meat and has an acceptable meat-like texture. Furthermore,
there is a need for a structured plant protein product that
simulates the taste and smell of seafood, while containing levels
of omega-3 fatty acids comparable to levels found in seafood rich
in omega-3 fatty acids.
SUMMARY OF THE INVENTION
[0005] One aspect of the present invention encompasses a simulated
seafood composition. Typically, the simulated seafood composition
comprises a structured plant protein product and a fatty acid.
[0006] Yet another aspect of the invention provides a simulated
seafood composition comprising a structured plant protein product,
wherein the structured plant protein product comprises protein
fibers that are substantially aligned, an omega-3 fatty acid; and
an appropriate colorant.
[0007] Still another aspect of the invention provides a simulated
seafood composition comprising a structured soy protein product,
wherein the structured soy protein product comprises protein fibers
that are substantially aligned; an omega-3 fatty acid; and an
appropriate colorant.
[0008] Other aspects and features of the invention are described in
more detail below.
FIGURE LEGENDS
[0009] The application file contains at least one photograph
executed in color. Copies of this patent application publication
with color photographs will be provided by the Office upon request
and payment of the necessary fee.
[0010] FIG. 1 depicts a photographic image of a micrograph showing
a structured plant protein product of the invention having protein
fibers that are substantially aligned.
[0011] FIG. 2 depicts a photographic image of a micrograph showing
a plant protein product not produced by the process of the present
invention. The protein fibers comprising the plant protein product,
as described herein, are crosshatched
DETAILED DESCRIPTION OF THE INVENTION
[0012] The present invention provides simulated seafood
compositions. Typically, the simulated seafood composition will
comprise structured plant protein products and fatty acids.
Alternatively, the simulated seafood composition will further
comprise seafood meat. In one embodiment, the simulated seafood
composition will comprise structured plant protein products having
protein fibers that are substantially aligned. In another
embodiment, the simulated seafood composition will comprise
coloring systems such that the simulated seafood composition has
the color and texture of seafood meat. In addition, the simulated
seafood composition also generally has the flavor, texture, and
smell of seafood meat. Further, the simulated seafood composition
can have levels of omega-3 fatty acids typically found in seafood
rich in omega-3 fatty acids.
Structured Plant Protein Products
[0013] The seafood compositions and simulated seafood compositions
of the invention each comprise structured plant protein products
comprising protein fibers that are substantially aligned, as
described in more detail in I(c) below. In an exemplary embodiment,
the structured plant protein products are extrudates of plant
materials that have been subjected to the extrusion process
detailed in I(b) below. Because the structured plant protein
products utilized the invention have protein fibers that are
substantially aligned in a manner similar to seafood meat, the
seafood compositions and simulated seafood compositions generally
have the texture and feel of compositions containing all seafood
meat.
Protein-Containing Starting Material
[0014] A variety of ingredients that contain protein may be
utilized in an extrusion process to produce structured plant
protein products suitable for use in the invention. While
ingredients comprising proteins derived from plants are typically
used, it is also envisioned that proteins derived from other
sources, such as animal sources, may be utilized without departing
from the scope of the invention. For example, a dairy protein
selected from the group consisting of casein, caseinates, whey
protein, milk protein concentrate, milk protein isolate, and
mixtures thereof may be utilized. In an exemplary embodiment, the
dairy protein is whey protein. By way of further example, an egg
protein selected from the group consisting of ovalbumin,
ovoglobulin, ovomucin, ovomucoid, ovotransferrin, ovovitelia,
ovovitellin, albumin globulin, and vitellin may be utilized.
[0015] It is envisioned that other ingredient types in addition to
proteins may be utilized. Not limiting examples of such ingredients
include sugars, starches, oligosaccharides, soy fiber and other
dietary fibers, and gluten.
[0016] It is also envisioned that the protein-containing starting
materials may be gluten-free. Because gluten is typically used in
filament formation during the extrusion process, if a gluten-free
starting material is used, an edible crosslink agent may be
utilized to facilitate filament formation. Non-limiting examples of
suitable crosslink agents include Konjac glucomannan (KGM) flour,
edible crosslink agents, Pureglucan manufactured by Takeda (USA),
calcium salts, and magnesium salts. One skilled in the art can
readily determine the amount of cross linker needed, if any, in
gluten-free embodiments.
[0017] Irrespective of its source or ingredient classification, the
ingredients utilized in the extrusion process are typically capable
of forming structured plant protein products having protein fibers
that are substantially aligned. Suitable examples of such
ingredients are detailed more fully below.
Plant Protein Materials
[0018] In an exemplary embodiment, at least one ingredient derived
from a plant will be utilized to form the protein-containing
materials. Generally speaking, the ingredient will comprise a
protein. The amount of protein present in the ingredient(s)
utilized can and will vary depending upon the application. For
example, the amount of protein present in the ingredient(s)
utilized may range from about 40% to about 100% by weight. In
another embodiment, the amount of protein present in the
ingredient(s) utilized may range from about 50% to about 100% by
weight. In an additional embodiment, the amount of protein present
in the ingredient(s) utilized may range from about 60% to about
100% by weight. In a further embodiment, the amount of protein
present in the ingredient(s) utilized may range from about 70% to
about 100% by weight. In still another embodiment, the amount of
protein present in the ingredient(s) utilized may range from about
80% to about 100% by weight. In a further embodiment, the amount of
protein present in the ingredient(s) utilized may range from about
90% to about 100% by weight.
[0019] The ingredient(s) utilized in extrusion may be derived from
a variety of suitable plants. By way of non-limiting example,
suitable plants include legumes, corn, peas, canola, sunflowers,
sorghum, rice, amaranth, potato, tapioca, arrowroot, canna, lupin,
rape seed, wheat, oats, rye, barley, and mixtures thereof.
[0020] In one embodiment, the ingredients are isolated from wheat
and soybeans. In another exemplary embodiment, the ingredients are
isolated from soybeans. Suitable wheat derived protein-containing
ingredients include wheat gluten, wheat flour, and mixtures
thereof. An example of commercially available wheat gluten that may
be utilized in the invention is Gem of the West Vital Wheat Gluten,
either regular or organic, available from Manildra Milling (Shawnee
Mission, Kans.). Suitable soybean derived protein-containing
ingredients ("soy protein material") include soy protein isolate,
soy protein concentrate, soy flour, and mixtures thereof, each of
which are detailed below. In each of the foregoing embodiments, the
soybean material may be combined with one or more ingredients
selected from the group consisting of a starch, flour, gluten, a
dietary fiber, and mixtures thereof.
[0021] Suitable examples of protein-containing material isolated
from a variety of sources are detailed in Table A, which shows
various combinations.
TABLE-US-00001 TABLE A Protein Combinations First protein source
second ingredient Soybean wheat Soybean dairy Soybean egg Soybean
corn Soybean rice Soybean barley Soybean sorghum Soybean oat
Soybean millet Soybean rye Soybean triticale Soybean buckwheat
Soybean pea Soybean peanut Soybean lentil Soybean lupin Soybean
channa (garbonzo) Soybean rapeseed (canola) Soybean cassava Soybean
sunflower Soybean whey Soybean tapioca Soybean arrowroot Soybean
amaranth Soybean wheat and dairy Soybean wheat and egg Soybean
wheat and corn Soybean wheat and rice Soybean wheat and barley
Soybean wheat and sorghum Soybean wheat and oat Soybean wheat and
millet Soybean wheat and rye Soybean wheat and triticale Soybean
wheat and buckwheat Soybean wheat and pea Soybean wheat and peanut
Soybean wheat and lentil Soybean wheat and lupin Soybean wheat and
channa (garbonzo) Soybean wheat and rapeseed (canola) Soybean wheat
and cassava Soybean wheat and sunflower Soybean wheat and potato
Soybean wheat and tapioca Soybean wheat and arrowroot Soybean wheat
and amaranth Soybean corn and wheat Soybean corn and dairy Soybean
corn and egg Soybean corn and rice Soybean corn and barley Soybean
corn and sorghum Soybean corn and oat Soybean corn and millet
Soybean corn and rye Soybean corn and triticale Soybean corn and
buckwheat Soybean corn and pea Soybean corn and peanut Soybean corn
and lentil Soybean corn and lupin Soybean corn and channa
(garbonzo) Soybean corn and rapeseed (canola) Soybean corn and
cassava Soybean corn and sunflower Soybean corn and potato Soybean
corn and tapioca Soybean corn and arrowroot Soybean corn and
amaranth
[0022] In each of the embodiments delineated in Table A, the
combination of protein-containing materials may be combined with
one or more ingredients selected from the group consisting of a
starch, flour, gluten, a dietary fiber, and mixtures thereof. In
one embodiment, the protein-containing material comprises protein,
starch, gluten, and fiber. In an exemplary embodiment, the
protein-containing material comprises from about 45% to about 65%
soy protein on a dry matter basis; from about 20% to about 30%
wheat gluten on a dry matter basis; from about 10% to about 15%
wheat starch on a dry matter basis; and from about 1% to about 5%
starch on a dry matter basis. In each of the foregoing embodiments,
the protein-containing material may comprise dicalcium phosphate,
L-cysteine or combinations of both dicalcium phosphate and
L-cysteine.
Soy Protein Materials
[0023] In an exemplary embodiment, as detailed above, soy protein
isolate, soy protein concentrate, soy flour, and mixtures thereof
may be utilized in the extrusion process. The soy protein materials
may be derived from whole soybeans in accordance with methods
generally known in the art. The whole soybean may be standard
soybeans (i.e., non genetically modified soybeans), commoditized
soybeans, hybridized soybeans, genetically modified soybeans, and
combinations thereof.
[0024] Generally speaking, when soy isolate is used, an isolate is
preferably selected that is not a highly hydrolyzed soy protein
isolate. In certain embodiments, highly hydrolyzed soy protein
isolates, however, may be used in combination with other soy
protein isolates provided that the highly hydrolyzed soy protein
isolate content of the combined soy protein isolates is generally
less than about 40% of the combined soy protein isolates, by
weight. Examples of soy protein isolates that are useful in the
present invention are commercially available, for example, from
Solae, LLC (St. Louis, Mo.), and include SUPRO.RTM. 500E,
SUPRO.RTM. EX 33, SUPRO.RTM. 620, and SUPRO.RTM. 545. In an
exemplary embodiment, a form of SUPRO.RTM. 620 is utilized as
detailed in Example 5.
[0025] Alternatively, soy protein concentrate or soy flour may be
blended with the soy protein isolate to substitute for a portion of
the soy protein isolate as a source of soy protein material.
Typically, if a soy protein concentrate is substituted for a
portion of the soy protein isolate, the soy protein concentrate is
substituted for up to about 40% of the soy protein isolate by
weight, at most, and more preferably is substituted for up to about
30% of the soy protein isolate by weight. Examples of suitable soy
protein concentrates useful in the invention include Procon, Alpha
12 and Alpha 5800, which are commercially available from Solae, LLC
(St. Louis, Mo.). If a soy flour is substituted for a portion of
the soy protein isolate, the soy flour is substituted for up to
about 35% of the soy protein isolate by weight. The soy flour
should be a high protein dispersibility index (PDI) soy flour.
[0026] Any fiber known in the art that will work in the application
can be used as the fiber source. Soy cotyledon fiber may be
utilized as a fiber source. Suitable soy cotyledon fiber will
generally effectively bind water when the mixture of soy protein
and soy cotyledon fiber is extruded. In this context, "effectively
bind water" generally means that the soy cotyledon fiber has a
water holding capacity of at least 5.0 to about 8.0 grams of water
per gram of soy cotyledon fiber, and preferably the soy cotyledon
fiber has a water holding capacity of at least about 6.0 to about
8.0 grams of water per gram of soy cotyledon fiber. When present in
the soy protein material, soy cotyledon fiber may be present in an
amount ranging from about 1% to about 20%, preferably from about
1.5% to about 20% and most preferably, at from about 2% to about 5%
by weight on a moisture free basis. Suitable soy cotyledon fiber is
commercially available. For example, FIBRIM.RTM. 1260 and
FIBRIM.RTM. 2000 are soy cotyledon fiber materials that are
commercially available from Solae, LLC (St. Louis, Mo.).
Additional Ingredients
[0027] A variety of additional ingredients may be added to any of
the combinations of protein-containing materials above without
departing from the scope of the invention. For example,
antioxidants, antimicrobial agents, and combinations thereof may be
included. Antioxidant additives include BHA, BHT, TBHQ, vitamins A,
C and E and derivatives, and various plant extracts such as those
containing carotenoids, tocopherols or flavonoids having
antioxidant properties, may be included to increase the shelf-life
or nutritionally enhance the seafood compositions or simulated
seafood compositions. The antioxidants and the antimicrobial agents
may have a combined presence at levels of from about 0.01% to about
10%, preferably, from about 0.05% to about 5%, and more preferably
from about 0.1% to about 2%, by weight of the protein-containing
materials that will be extruded.
Moisture Content
[0028] As will be appreciated by the skilled artisan, the moisture
content of the protein-containing materials can and will vary
depending upon the extrusion process. Generally speaking, the
moisture content may range from about 1% to about 80% by weight. In
low moisture extrusion applications, the moisture content of the
protein-containing materials may range from about 1% to about 35%
by weight. Alternatively, in high moisture extrusion applications,
the moisture content of the protein-containing materials may range
from about 35% to about 80% by weight. In an exemplary embodiment,
the extrusion application utilized to form the extrudates is low
moisture. An exemplary example of a low moisture extrusion process
to produce extrudates having proteins with fibers that are
substantially aligned is detailed in I(b) and Example 5.
Extrusion of the Plant Material
[0029] A suitable extrusion process for the preparation of a
structured plant protein product comprises introducing the plant
protein material and other ingredients into a mixing tank (i.e., an
ingredient blender) to combine the ingredients and form a dry
blended plant protein material pre-mix. The dry blended plant
protein material pre-mix is then transferred to a hopper from which
the dry blended ingredients are introduced along with moisture into
a pre-conditioner to form a conditioned plant protein material
mixture. The conditioned material is then fed to an extruder in
which the plant protein material mixture is heated under mechanical
pressure generated by the screws of the extruder to form a molten
extrusion mass. The molten extrusion mass exits the extruder
through an extrusion die.
Extrusion Process Conditions
[0030] Among the suitable extrusion apparatuses useful in the
practice of the present invention is a double barrel, twin-screw
extruder as described, for example, in U.S. Pat. No. 4,600,311.
Further examples of suitable commercially available extrusion
apparatuses include a CLEXTRAL Model BC-72 extruder manufactured by
Clextral, Inc. (Tampa, Fla.); a WENGER Model TX-57 extruder, a
WENGER Model TX-168 extruder, and a WENGER Model TX-52 extruder all
manufactured by Wenger Manufacturing, Inc. (Sabetha, Kans.). Other
conventional extruders suitable for use in this invention are
described, for example, in U.S. Pat. Nos. 4,763,569, 4,118,164, and
3,117,006, which are hereby incorporated by reference in their
entirety. A single-screw extruder could also be used in the present
invention. Examples of suitable commercially available single-screw
extrusion apparatuses include the Wenger X-175, the Wenger X-165,
and the Wenger X-85 all of which are available from Wenger
Manufacturing, Inc.
[0031] The screws of a twin-screw extruder can rotate within the
barrel in the same or opposite directions. Rotation of the screws
in the same direction is referred to as single flow or co-rotating
whereas rotation of the screws in opposite directions is referred
to as double flow or counter-rotating. The speed of the screw or
screws of the extruder may vary depending on the particular
apparatus; however, it is typically from about 250 to about 450
revolutions per minute (rpm). Generally, as the screw speed
increases, the density of the extrudate will decrease. The
extrusion apparatus contains screws assembled from shafts and worm
segments, as well as mixing lobe and ring-type shearing elements as
recommended by the extrusion apparatus manufacturer for extruding
plant protein material.
[0032] The extrusion apparatus generally comprises a plurality of
heating zones through which the protein mixture is conveyed under
mechanical pressure prior to exiting the extrusion apparatus
through an extrusion die. The temperature in each successive
heating zone generally exceeds the temperature of the previous
heating zone by between about 10.degree. C. to about 70.degree. C.
In one embodiment, the conditioned pre-mix is transferred through
four heating zones within the extrusion apparatus, with the protein
mixture heated to a temperature of from about 100.degree. C. to
about 150.degree. C. such that the molten extrusion mass enters the
extrusion die at a temperature of from about 100.degree. C. to
about 150.degree. C. There is no active heating or cooling
necessary. Typically, temperature changes are due to work input and
can happen suddenly.
[0033] The pressure within the extruder barrel is typically about
50 psig to about 500 psig, preferably between about 75 psig to
about 200 psig. Generally the pressure within the last two heating
zones is from about 100 psig to about 3000 psig. The barrel
pressure is dependent on numerous factors including, for example,
the extruder screw speed, feed rate of the mixture to the barrel,
feed rate of water to the barrel, and the viscosity of the molten
mass within the barrel.
[0034] Water is injected into the extruder barrel to hydrate the
plant protein material mixture and promote texturization of the
proteins. As an aid in forming the molten extrusion mass, the water
may act as a plasticizing agent. Water may be introduced to the
extruder barrel via one or more injection jets. Typically, the
mixture in the barrel contains from about 15% to about 35% by
weight water. The rate of introduction of water to any of the
heating zones is generally controlled to promote production of an
extrudate having desired characteristics. It has been observed that
as the rate of introduction of water to the barrel decreases, the
density of the extrudate decreases. Typically, less than about 1 kg
of water per kg of protein is introduced to the barrel. Preferably,
from about 0.1 kg to about 1 kg of water per kg of protein are
introduced to the barrel.
Preconditioning
[0035] In a pre-conditioner, the plant protein material and other
ingredients can be preheated, contacted with moisture, and held
under controlled temperature and pressure conditions to allow the
moisture to penetrate and soften the individual particles. The
preconditioner contains one or more paddles to promote uniform
mixing of the protein and transfer of the protein mixture through
the preconditioner. The configuration and rotational speed of the
paddles vary widely, depending on the capacity of the
preconditioner, the extruder throughput and/or the desired
residence time of the mixture in the preconditioner or extruder
barrel. Generally, the speed of the paddles is from about 100 to
about 1300 revolutions per minute (rpm). Agitation must be high
enough to obtain even hydration and good mixing.
[0036] Typically, the protein-containing material mixture is
pre-conditioned prior to introduction into the extrusion apparatus
by contacting the pre-mix with moisture (i.e., steam and/or water).
Preferably the protein-containing mixture is heated to a
temperature of from about 25.degree. C. to about 80.degree. C.,
more preferably from about 30.degree. C. to about 40.degree. C. in
the preconditioner.
[0037] Typically, the plant protein material pre-mix is conditioned
for a period of about 30 to about 60 seconds, depending on the
speed and the size of the conditioner. The plant protein material
pre-mix is contacted with steam and/or water and heated in the
pre-conditioner at generally constant steam flow to achieve the
desired temperatures. The water and/or steam conditions (i.e.,
hydrates) the plant protein material mixture, increases its
density, and facilitates the flowability of the dried mix without
interference prior to introduction to the extruder barrel where the
proteins are texturized. If a low moisture plant protein material
is desired, the conditioned pre-mix may contain from about 1% to
about 35% (by weight) water. If a high moisture plant protein
material is desired, the conditioned pre-mix may contain from about
35% to about 80% (by weight) water.
[0038] The conditioned pre-mix typically has a bulk density of from
about 0.25 g/cm.sup.3 to about 0.6 g/cm.sup.3. Generally, as the
bulk density of the pre-conditioned protein mixture increases
within this range, the protein mixture is easier to process.
Extrusion Process
[0039] The conditioned pre-mix is then fed into an extruder to
heat, shear, and ultimately plasticize the mixture. The extruder
may be selected from any commercially available extruder and may be
a single-screw extruder or preferably a twin-screw extruder that
mechanically shears the mixture with the screw elements.
[0040] Whichever extruder is used, it should be run in excess of
about 50% motor load. Typically the conditioned pre-mix is
introduced to the extrusion apparatus at a rate of between about 16
kilograms per minute to about 60 kilograms per minute. More
preferably, the conditioned pre-mix is introduced to the extrusion
apparatus at a rate of between about 26 kilograms per minute to
about 32 kilograms per minute. Generally, it has been observed that
the density of the extrudate decreases as the feed rate of pre-mix
to the extruder increases.
[0041] The protein mixture is subjected to shear and pressure by
the extruder to plasticize the mixture. The screw elements of the
extruder shear the mixture as well as create pressure in the
extruder by forcing the mixture forwards though the extruder and
through the die. The screw motor speed determines the amount of
shear and pressure applied to the mixture by the screw(s).
Preferably, the screw motor speed is set to a speed of from about
200 rpm to about 500 rpm, and more preferably from about 300 rpm to
about 450 rpm, which moves the mixture through the extruder at a
rate of at least about 20 kilograms per minute, and more preferably
at least about 40 kilograms per minute. Preferably the extruder
generates an extruder barrel exit pressure of from about 50 psig to
about 3000 psig.
[0042] The extruder heats the protein mixture as it passes through
the extruder denaturing the protein in the mixture. The extruder
includes a means for heating the mixture to temperatures of from
about 100.degree. C. to about 180.degree. C. Preferably the means
for heating the mixture in the extruder comprises extruder barrel
jackets into which heating or cooling media such as steam or water
may be introduced to control the temperature of the mixture passing
through the extruder. The extruder may also include steam injection
ports for directly injecting steam into the mixture within the
extruder. The extruder preferably includes multiple heating zones
that can be controlled to independent temperatures, where the
temperatures of the heating zones are preferably set to increase
the temperature of the mixture as it proceeds through the extruder.
For example, the extruder may be set in a four temperature zone
arrangement, where the first zone (adjacent the extruder inlet
port) is set to a temperature of from about 80.degree. C. to about
100.degree. C., the second zone is set to a temperature of from
about 100.degree. C. to 135.degree. C., the third zone is set to a
temperature of from 135.degree. C. to about 150.degree. C., and the
fourth zone (adjacent the extruder exit port) is set to a
temperature of from 150.degree. C. to 180.degree. C. The extruder
may be set in other temperature zone arrangements, as desired. For
example, the extruder may be set in a five temperature zone
arrangement, where the first zone is set to a temperature of about
25.degree. C., the second zone is set to a temperature of about
50.degree. C., the third zone is set to a temperature of about
95.degree. C., the fourth zone is set to a temperature of about
130.degree. C., and the fifth zone is set to a temperature of about
150.degree. C.
[0043] The mixture forms a melted plasticized mass in the extruder.
A die assembly is attached to the extruder in an arrangement that
permits the plasticized mixture to flow from the extruder exit port
into the die assembly, wherein the die assembly consists of a die
and a back plate. Additionally, the die assembly produces
substantial alignment of the protein fibers within the plasticized
mixture as it flows through the die assembly. The back plate in
combination with the die create at least one central chamber that
receives the melted plasticized mass from the extruder through at
least one central opening. From the at least one central chamber,
the melted plasticized mass is directed by flow directors into at
least one elongated tapered channel. Each elongated tapered channel
leads directly to an individual die aperture. The extrudate exits
the die through at least one aperture in the periphery or side of
the die assembly at which point the protein fibers contained within
are substantially aligned. It is also contemplated that the
extrudate may exit the die assembly through at least one aperture
in the die face, which may be a die plate affixed to the die.
[0044] The width and height dimensions of the die aperture(s) are
selected and set prior to extrusion of the mixture to provide the
fibrous material extrudate with the desired dimensions. The width
of the die aperture(s) may be set so that the extrudate resembles
from a cubic chunk of meat to a steak filet, where widening the
width of the die aperture(s) decreases the cubic chunk-like nature
of the extrudate and increases the filet-like nature of the
extrudate. Preferably the width of the die aperture(s) is/are set
to a width of from about 5 millimeters to about 40 millimeters.
[0045] The height dimension of the die aperture(s) may be set to
provide the desired thickness of the extrudate. The height of the
aperture(s) may be set to provide a very thin extrudate or a thick
extrudate. Preferably, the height of the die aperture(s) may be set
to from about 1 millimeter to about 30 millimeters, and more
preferably from about 8 millimeters to about 16 millimeters.
[0046] It is also contemplated that the die aperture(s) may be
round. The diameter of the die aperture(s) may be set to provide
the desired thickness of the extrudate. The diameter of the
aperture(s) may be set to provide a very thin extrudate or a thick
extrudate. Preferably, the diameter of the die aperture(s) may be
set to from about 1 millimeter to about 30 millimeters, and more
preferably from about 8 millimeters to about 16 millimeters.
[0047] The extrudate can be cut after exiting the die assembly.
Suitable apparatuses for cutting the extrudate after it exits the
die assembly include flexible knives manufactured by Wenger
Manufacturing, Inc. (Sabetha, Kans.) and Clextral, Inc. (Tampa,
Fla.). Alternatively, a delayed cut can be done to the extrudate.
One such example of a delayed cut device is a guillotine
device.
[0048] The dryer, if one is used, generally comprises a plurality
of drying zones in which the air temperature may vary. The
extrudate will be present in the dryer for a time sufficient to
provide an extrudate having a desired moisture content. Thus, the
temperature of the air is not important, if a lower temperature is
used, longer drying times will be required than if a higher
temperature is used. Generally, the temperature of the air within
one or more of the zones will be from about 100.degree. C. to about
185.degree. C. At such temperatures, the extrudate is generally
dried for at least about 5 minutes and more generally, for at least
about 10 minutes. Suitable dryers include those manufactured by
Wolverine Proctor & Schwartz (Merrimac, Mass.), National Drying
Machinery Co. (Philadelphia, Pa.), Wenger (Sabetha, Kans.),
Clextral (Tampa, Fla.), and Buehler (Lake Bluff, Ill.).
[0049] The desired moisture content may vary widely depending on
the intended application of the extrudate. Generally speaking, the
extruded material has a moisture content of from about 6% to about
13% by weight, if dried. Although not required in order to separate
the fibers, hydrating in water until the water is absorbed is one
way to separate the fibers. If the protein material is not dried or
not fully dried, its moisture content is higher, generally from
about 16% to about 30% by weight, on a moisture free basis.
[0050] The dried extrudate may further be comminuted to reduce the
average particle size of the extrudate. Suitable grinding or
processing apparatus include hammer mills such as Mikro Hammer
Mills manufactured by Hosokawa Micron Ltd. (England), Fitzmill.RTM.
manufactured by The Fitzpatrick Company (Elmhurst, Ill.),
Comitrol.RTM. processors made by Urschel Laboratories (Valparaiso,
Ind.), and roller mills such as Rosskamp Roller Mills manufactured
by RossKamp Champion (Waterloo, Iowa). The size of the particles
can and will vary depending upon the seafood or seafood preparation
to be simulated. As an example, structured plant protein products
may be cut into chunks, which have dimensions of not less than 1.2
cm in each direction and in which the original substantially
aligned protein fibers are retained. Alternatively, structured
plant protein products may also be cut into flakes, which have
dimensions less than 1.2 cm in each direction but in which the
aligned protein fibers are essentially retained. Furthermore,
structured plant protein products may be grated or shredded, in
which discrete particles of uniform size are produced.
Characterization of the Structured Plant Protein Products
[0051] The extrudates produced in I(b) typically comprise the
structured plant protein products comprising protein fibers that
are substantially aligned. In the context of this invention
"substantially aligned" generally refers to the arrangement of
protein fibers such that a significantly high percentage of the
protein fibers forming the structured plant protein product are
contiguous to each other at less than approximately a 45.degree.
angle when viewed in a horizontal plane. Typically, an average of
at least 55% of the protein fibers comprising the structured plant
protein product are substantially aligned. In another embodiment,
an average of at least 60% of the protein fibers comprising the
structured plant protein product are substantially aligned. In a
further embodiment, an average of at least 70% of the protein
fibers comprising the structured plant protein product are
substantially aligned. In an additional embodiment, an average of
at least 80% of the protein fibers comprising the structured plant
protein product are substantially aligned. In yet another
embodiment, an average of at least 90% of the protein fibers
comprising the structured plant protein product are substantially
aligned Methods for determining the degree of protein fiber
alignment are known in the art and include visual determinations
based upon micrographic images. By way of example, FIGS. 1 and 2
depict micrographic images that illustrate the difference between a
structured plant protein product having substantially aligned
protein fibers compared to a plant protein product having protein
fibers that are significantly crosshatched. FIG. 1 depicts a
structured plant protein product prepared according to I(a)-I(b)
having protein fibers that are substantially aligned.
Contrastingly, FIG. 2 depicts a plant protein product containing
protein fibers that are significantly crosshatched and not
substantially aligned. Because the protein fibers are substantially
aligned, as shown in FIG. 1, the structured plant protein products
utilized in the invention generally have the texture and
consistency of cooked muscle meat. In contrast, extrudates having
protein fibers that are randomly oriented or crosshatched generally
have a texture that is soft or spongy.
[0052] In addition to having protein fibers that are substantially
aligned, the structured plant protein products also typically have
shear strength substantially similar to whole meat muscle. In this
context of the invention, the term "shear strength" provides one
means to quantify the formation of a sufficient fibrous network to
impart whole-muscle like texture and appearance to the plant
protein product. Shear strength is the maximum force in grams
needed to puncture through a given sample. A method for measuring
shear strength is described in Example 3. Generally speaking, the
structured plant protein products of the invention will have
average shear strength of at least 1400 grams. In an additional
embodiment, the structured plant protein products will have average
shear strength of from about 1500 to about 1800 grams. In yet
another embodiment, the structured plant protein products will have
average shear strength of from about 1800 to about 2000 grams. In a
further embodiment, the structured plant protein products will have
average shear strength of from about 2000 to about 2600 grams. In
an additional embodiment, the structured plant protein products
will have average shear strength of at least 2200 grams. In a
further embodiment, the structured plant protein products will have
average shear strength of at least 2300 grams. In yet another
embodiment, the structured plant protein products will have average
shear strength of at least 2400 grams. In still another embodiment,
the structured plant protein products will have average shear
strength of at least 2500 grams. In a further embodiment, the
structured plant protein products will have average shear strength
of at least 2600 grams.
[0053] A means to quantify the size of the protein fibers formed in
the structured plant protein products may be done by a shred
characterization test. Shred characterization is a test that
generally determines the percentage of large pieces formed in the
structured plant protein product. In an indirect manner, percentage
of shred characterization provides an additional means to quantify
the degree of protein fiber alignment in a structured plant protein
product. Generally speaking, as the percentage of large pieces
increases, the degree of protein fibers that are aligned within a
structured plant protein product also typically increases.
Conversely, as the percentage of large pieces decreases, the degree
of protein fibers that are aligned within a structured plant
protein product also typically decreases. A method for determining
shred characterization is detailed in Example 4. The structured
plant protein products of the invention typically have an average
shred characterization of at least 10% by weight of large pieces.
In a further embodiment, the structured plant protein products have
an average shred characterization of from about 10% to about 15% by
weight of large pieces. In another embodiment, the structured plant
protein products have an average shred characterization of from
about 15% to about 20% by weight of large pieces. In yet another
embodiment, the structured plant protein products have an average
shred characterization of from about 20% to about 50% by weight of
large pieces. In another embodiment, the average shred
characterization is at least 20% by weight, at least 21% by weight,
at least 22% by weight, at least 23% by weight, at least 24% by
weight, at least 25% by weight, or at least 26% by weight large
pieces.
[0054] Suitable structured plant protein products of the invention
generally have protein fibers that are substantially aligned, have
average shear strength of at least 1400 grams, and have an average
shred characterization of at least 10% by weight large pieces. More
typically, the structured plant protein products will have protein
fibers that are at least 55% aligned, have average shear strength
of at least 1800 grams, and have an average shred characterization
of at least 15% by weight large pieces. In exemplary embodiment,
the structured plant protein products will have protein fibers that
are at least 55% aligned, have average shear strength of at least
2000 grams, and have an average shred characterization of at least
17% by weight large pieces. In another exemplary embodiment, the
structured plant protein products will have protein fibers that are
at least 55% aligned, have average shear strength of at least 2200
grams, and have an average shred characterization of at least 20%
by weight large pieces.
Fatty Acids
[0055] The simulated seafood composition, in addition to structured
plant protein products, also comprises fatty acids. The fatty acid
will generally range in length from about 10 to 26 carbon atoms,
and preferably in the range of 18 to 22 carbons. The fatty acid may
be a saturated fatty acid or an unsaturated fatty acid. The
unsaturated fatty acid may be monounsaturated or polyunsaturated.
The polyunsaturated fatty acid (PUFA) may be an omega-3 fatty acid
in which the first double bond occurs in the third carbon-carbon
bond from the methyl end (opposite the acid group) of the carbon
chain. Examples of omega-3 fatty acids include alpha-linolenic acid
(18:3, ALA), stearidonic acid (18:4, SDA), eicosatetraenoic acid
(20:4), eicosapentaenoic acid (20:5; EPA), and docosahexaenoic acid
(22:6; DHA). The PUFA may be an omega-6 fatty acid, in which the
first double bond occurs in the sixth carbon-carbon bond from the
methyl end. Examples of omega-6 fatty acids include linoleic acid
(18:2), gamma-linolenic acid (18:3), eicosadienoic acid (20:2),
dihomo-gamma-linolenic acid (20:3), arachidonic acid (20:4),
docosadienoic acid (22:2), adrenic acid (22:4), and
docosapentaenoic acid (22:5). The fatty acid may be an omega-9
fatty acid, such as oleic acid (18:1), eicosenoic acid (20:1), mead
acid (20:3), erucic acid (22:1), and nervonic acid (24:1). The
fatty acid may be one of the aforementioned fatty acids or a
combination of the aforementioned fatty acids.
[0056] The fatty acid will be an essentially pure fatty acid that
is devoid of contaminants and odorants. The fatty acid may be
derived from an appropriate plant or seafood source. PUFAs and, in
particular, omega-3 and omega-6 fatty acids are primarily found in
plants and seafood. The ratio of omega-3 to omega-6 fatty acids in
seafood ranges from about 8:1 to 20:1. Seafood rich in omega-3
fatty acids include anchovies, catfish, clams, cod, herring, lake
trout, mackerel, salmon, sardines, shrimp, and tuna.
[0057] The concentration of the fatty acid in the simulated seafood
compositions may range from about 0.0001% to about 1%, and
preferably from about 0.001% to about 0.05%.
Seafood Meat
[0058] The simulated seafood composition, in addition to structured
plant protein products and fatty acids, may also comprise seafood
meat. Generally speaking, the seafood meat may be obtained from a
variety of seafood species suitable for human consumption. Suitable
examples of seafood include fish, both fresh water and salt water
fish, such as amberjack, anchovies, bluefish, bonito, bowfin,
bream, buffalofish, burbot, butterfish, carp, catfish, crevalle
jack, cobia, cod, croaker, cusk, eel, gar, grouper, flounder
(arrowtooth, southern, starry, summer, winter, witch, yellowtail),
haddock, jewfish, kingfish, lake chub, lake herring, lake sturgeon,
lake whitefish, lingcod, mackerel (Atlantic, king, Spanish), mahi
mahi, monkfish, mullet, muskie, pike, orange roughy, Pacific sand
dab, paddlefish, perch, pollock, pompano, rockfish, sable, salmon
(Atlantic, chum, Chinook, coho or silver, pink, sockeye or red),
sauger, sculp, sea bass (black, giant, white), sea dab, shark,
sheepshead, smelt, snakehead, snapper (red, mangrove, vermillion,
yellowtail), snook, sole (Dover, English, Petrale, Rex, rock),
spot, spotted cabrilla, bass, sturgeon, swordfish, tautog,
tilefish, turbot, trout (brook, lake, rainbow, sea, white sea),
tuna (albacore, Atlantic bluefin, big eye, blackfin, skipjack,
southern bluefin, tongol, yellowtail), walleye, crappie, whiting,
and wolfish. Seafood also includes shellfish and crustaceans such
as crabs (Alaskan, blue, Dungeness, Jonah, red, softshell, snow)
clams (butter, Goeduck, hard, littleneck, razor, steamer), shrimp
(blue, brown, California, Key West, northern, pink, rock, tiger,
white), lobster (American, rock, slipper, spiny), mollusks
(abalone, cockle, conch, welk), mussels (blue, California, green
lip), octopus, oysters (Apalachicola, Atlantic, gulf, Olympia,
Pacific, soft American), scallops (bay, calico, sea), and
squid.
[0059] The seafood meat may be fresh or cooked before it is added
to the simulated seafood composition. The seafood meat may include
animal flesh trim and animal tissues derived from processing such
as the frozen residue from sawing frozen fish. Seafood meat may
also include fish skin and mechanically separated fish. The seafood
meat may be cooked by steam, water, oil, hot air, smoke, or a
combination thereof. The seafood meat is generally heated until the
internal temperature is between 60.degree. C. and 85.degree. C. The
simulated seafood composition comprising structured plant protein
products and seafood meat may or may not be cooked further prior to
or during packaging.
[0060] Typically, the amount of structured plant protein product in
relation to the amount of seafood meat in the simulated seafood
composition can and will vary depending upon the composition's
intended use. By way of example, when a significantly vegetarian
composition that has a relatively small degree of seafood flavor is
desired, the concentration of seafood meat in the simulated seafood
composition may be about 45%, 40%, 35%, 30%, 25%, 20%, 15%, 10%,
5%, 2%, or 0% by weight. Alternatively, when a simulated seafood
composition having a relatively high degree of seafood flavor or
seafood meat is desired, the concentration of seafood meat in the
simulated seafood composition may be about 50%, 55%, 60%, 65%, 70%,
or 75% by weight. Consequently, the concentration of structured
plant protein product in the simulated seafood composition may be
about 25%, 30%, 35%, 40%, 45%, 50%, 55%, 60%, 65%, 70%, 75%, 80%,
85%, 90%, 95%, or 99% by weight.
Other Additives for Simulated Seafood Compositions
[0061] Another aspect of the invention provides a simulated seafood
composition, which further comprises an appropriate colorant. The
simulated seafood compositions may further comprise antioxidants,
flavoring agents, or additional nutrients.
Colorants
[0062] The structured plant protein products generally will be
colored to resemble the color of the seafood flesh it will simulate
in the simulated seafood composition. In one embodiment, the
structured plant protein product will be colored to resemble
retorted tuna meat or salmon meat. In another embodiment, the
structured plant protein product will be colored to resemble
chopped shrimp. The composition of the structured plant protein
product was described above in I(a). The structured plant protein
product used in the simulated seafood composition, as an exemplary
example, may comprise soy protein and wheat protein.
[0063] The structured plant protein products may be colored with a
natural colorant, a combination of natural colorants, an artificial
colorant, a combination of artificial colorants, or a combination
of natural and artificial colorants. Suitable examples of natural
colorants include annatto (reddish-orange), anthocyanins (red,
purple, bleu), beet juice, beta-carotene (yellow to orange),
beta-APO 8 carotenal (orange to red), black currant, burnt sugar;
canthaxanthin (orange), caramel, carmine/carminic acid (magenta,
pink, red), carrot, cochineal extract (magenta, pink, red),
curcumin (yellow-orange); grape, hibiscus (blue-red), lac red,
lutein (yellow); monascus red, paprika, red cabbage juice,
redfruit, riboflavin (yellow-orange), saffron, titanium dioxide
(white), and turmeric (yellow-orange). Examples of FDA-approved
artificial colorants include FD&C (Food Drug & Cosmetics)
Red No. 3 (Erythrosine), Red No. 40 (Allura Red AC), Yellow No. 5
(Tartrazine), Yellow No. 6 (Sunset Yellow), Blue No. 1 (Brilliant
Blue FCF), and Blue No. 2 (Indigotine). Food colorants may be dyes,
which are powders, granules, or liquids that are soluble in water.
Alternatively, natural and artificial food colorants may be lake
colors, which are combinations of dyes and insoluble materials.
Lake colors are not oil soluble, but are oil dispersible; they tint
by dispersion.
[0064] The type of colorant or colorants and the concentration of
the colorant or colorants will be adjusted to match the color of
the seafood meat to be simulated. The final concentration of a
natural food colorant in a simulated seafood composition may range
from about 0.01% percent to about 4% by weight, preferably in the
range from about 0.03% to about 2% by weight, and more preferably
in the range from about 0.1% to about 1% by weight. The final
concentration of an artificial food colorant in a simulated seafood
composition may range from about 0.000001% to about 0.2% by weight,
preferably in the range from about 0.00001% to about 0.02% by
weight, and more preferably in the range from about 0.0001% to
about 0.002% by weight.
[0065] During the coloring process, the structured plant protein
products are generally mixed with water to rehydrate the structured
plant protein product. The amount of water added to the plant
protein product can and will vary. The ratio of water to structured
plant protein product may range from about 1:1 to about 10:1. In a
preferred embodiment, the ration of water to structured plant
protein product may range from about 2:1 to about 3:1.
[0066] The coloring system may further comprise an acidity
regulator to maintain the pH in the optimal range for the colorant.
The acidity regulator may be an acidulent. Examples of acidulents
that may be added to food include citric acid, acetic acid
(vinegar), tartaric acid, malic acid, fumaric acid, lactic acid,
phosphoric acid, sorbic acid, and benzoic acid. The final
concentration of the acidulent in a simulated seafood composition
may range from about 0.001% to about 5% by weight. The final
concentration of the acidulent may range from about 0.01% to about
2% by weight. The final concentration of the acidulent may range
from about 0.1% to about 1% by weight. The acidity regulator may
also be a pH-raising agent, such as disodium diphosphate.
Antioxidants
[0067] The simulated seafood composition may further comprise an
antioxidant. The antioxidant may prevent the oxidation of the
polyunsaturated fatty acids (e.g., omega-3 fatty acids) in the
simulated seafood composition, and the antioxidant may also prevent
oxidative color changes in the colored structured plant protein
product and the seafood meat. The antioxidant may be natural or
synthetic. Suitable antioxidants include, but are not limited to,
ascorbic acid and its salts, ascorbyl palmitate, ascorbyl stearate,
anoxomer, N-acetylcysteine, benzyl isothiocyanate, o-, m- or
p-amino benzoic acid (o is anthranilic acid, p is PABA), butylated
hydroxyanisole (BHA), butylated hydroxytoluene (BHT), caffeic acid,
canthaxantin, alpha-carotene, beta-carotene, beta-caraotene,
beta-apo-carotenoic acid, carnosol, carvacrol, catechins, cetyl
gallate, chlorogenic acid, citric acid and its salts, clove
extract, coffee bean extract, p-coumaric acid, 3,4-dihydroxybenzoic
acid, N,N'-diphenyl-p-phenylenediamine (DPPD), dilauryl
thiodipropionate, distearyl thiodipropionate,
2,6-di-tert-butylphenol, dodecyl gallate, edetic acid, ellagic
acid, erythorbic acid, sodium erythorbate, esculetin, esculin,
6-ethoxy-1,2-dihydro-2,2,4-trimethylquinoline, ethyl gallate, ethyl
maltol, ethylenediaminetetraacetic acid (EDTA), eucalyptus extract,
eugenol, ferulic acid, flavonoids, flavones (e.g., apigenin,
chrysin, luteolin), flavonols (e.g., datiscetin, myricetin,
daemfero), flavanones, fraxetin, fumaric acid, gallic acid, gentian
extract, gluconic acid, glycine, gum guaiacum, hesperetin,
alpha-hydroxybenzyl phosphinic acid, hydroxycinammic acid,
hydroxyglutaric acid, hydroquinone, N-hydroxysuccinic acid,
hydroxytryrosol, hydroxyurea, ice bran extract, lactic acid and its
salts, lecithins, lecithin citrate; R-alpha-lipoic acid, lutein,
lycopene, malic acid, maltol, 5-methoxy tryptamine, methyl gallate,
monoglyceride citrate; monoisopropyl citrate; morin,
beta-naphthoflavone, nordihydroguaiaretic acid (NDGA), octyl
gallate, oxalic acid, palmityl citrate, phenothiazine,
phosphatidylcholine, phosphoric acid, phosphates, phospholipids
such as phosphatidyl inositol, phosphatidyl ethanolamine,
phosphatidyl serine, and phosphatidic acid, phytic acid,
phytylubichromel, pimento extract, propyl gallate. polyphosphates,
quercetin, trans-resveratrol, rosemary extract, rosmarinic acid,
sage extract, sesamol, silymarin, sinapic acid, succinic acid,
stearyl citrate, syringic acid, tartaric acid, thymol, tocopherols
(i.e., alpha-, beta-, gamma- and delta-tocopherol), tocotrienols
(i.e., alpha-, beta-, gamma- and delta-tocotrienols), tyrosol,
vanilic acid. 2,6-di-tert-butyl-4-hydroxymethylphenol (i.e., lonox
100), 2,4-(tris-3',5'-bi-tert-butyl-4'-hydroxybenzyl)-mesitylene
(i.e., lonox 330), 2,4,5-trihydroxybutyrophenone, ubiquinone,
tertiary butyl hydroquinone (TBHQ), thiodipropionic acid,
trihydroxy butyrophenone, tryptamine, tyramine, uric acid, vitamin
K and derivates, vitamin Q10, wheat germ oil, zeaxanthin, or
combinations thereof. The concentration of an antioxidant in a
simulated seafood composition may range from about 0.0001% to about
20% by weight. The concentration of an antioxidant in a simulated
seafood composition may range from about 0.001% to about 5% by
weight. The concentration of an antioxidant in a simulated seafood
composition may range from about 0.01% to about 1%.
[0068] The simulated seafood composition may further comprise a
chelating agent to stabilize the color. Suitable examples of
chelating agents approved for use in food include
ethylenediaminetetraacetic acid (EDTA), citric acid, gluconic acid,
and phosphoric acid.
Flavoring Agents
[0069] The simulated seafood composition may further comprise a
flavoring agent to impart the flavor and smell of seafood meat. The
flavoring agent may be seafood oil or SDA. Generally, seafood oil
contains high amounts of EPA and DHA, with smaller amounts of
omega-6 fatty acids, 18C omega-3 fatty acids, 16C-22C unsaturated
fatty acids, and 12C-18C saturated fatty acids. The seafood oil may
be from herring, mackerel, menhaden, salmon, sardine, shellfish,
shrimp, tuna, fish body, cod liver, fish liver, or shark liver. DHA
may also be derived from algae. SDA can be derived from soybeans.
The seafood oil may be health grade, pharmaceutical grade,
concentrated, refined, or distilled. The flavoring agent may also
be a seafood extract, seafood broth, or seafood liquor. The seafood
extract, broth, or liquor may be from herring, mackerel, menhaden,
salmon, sardine, shellfish, shrimp, or tuna. Alternatively, the
seafood extract, broth, or liquor may be from a milder tasting
seafood, such as cod, haddock, whitefish, flounder, or crab.
[0070] The simulated seafood composition may further comprise a
flavor agent that imparts additional flavors. Examples of such
agents include spices, spice oils, spice extracts, onion
flavorings, garlic flavorings, herbs, herb oils, herb extracts,
natural smoke solutions, and natural smoke extracts. The simulated
seafood composition may further comprise a flavor enhancer.
Examples of flavor enhancers that may be used include salt (sodium
chloride), glutamic acid salts (e.g., monosodium glutamate),
glycine salts, guanylic acid salts, inosinic acid salts,
5'-ribonucleotide salts, hydrolyzed proteins, and hydrolyzed
vegetable proteins.
Nutrient Fortification
[0071] The simulated seafood composition may further comprise a
nutrient such as a vitamin, a mineral, an antioxidant, or an herb.
Suitable vitamins include Vitamins A, C, and E, which are also
antioxidants, and Vitamins B and D. Examples of minerals that may
be added include the salts of aluminum, ammonium, calcium,
magnesium, and potassium. Herbs that may be added include basil,
celery leaves, chervil, chives, cilantro, parsley, oregano,
tarragon, and thyme.
[0072] The simulated seafood composition may further comprise a
thickening or a gelling agent, such as alginic acid and its salts,
agar, carrageenan and its salts, processed Eucheuma seaweed, gums
(carob bean, guar, tragacanth, and xanthan), pectins, sodium
carboxymethylcellulose, and modified starches.
(V). Packaging of the Simulated Seafood Compositions.
[0073] The packaging of the simulated seafood compositions can and
will vary depending upon the type of composition and its intended
use. The simulated seafood compositions may be packaged fresh,
frozen, canned, retorted, dried, or freeze dried. The compositions
may be packed under vacuum, modified atmosphere (e.g., under high
CO.sub.2), or at atmospheric pressure. Standards for food packaging
are well known in the art. Fresh, frozen, or dried simulated
seafood compositions may be packed in plastic wraps, shrink film,
plastic bags/pouches/containers, or composite (i.e., plastic and
foil) bags/pouches/containers. Canned or retorted simulated seafood
compositions may be packed in cans, glass containers, plastic
bags/pouches, or composite bags/pouches. Freeze dried simulated
seafood compositions may be vacuum packed in plastic bags/pouches
or composite bags/pouches. Additionally, the simulated seafood
compositions may be mixed with vegetables, pasta, rice, beans,
animal meats, cheese, dairy products, or eggs to make seafood
entrees, meatless entrees, meat-seafood entrees, appetizers, stews,
soups, salads, omelets, etc. prior to packaging.
Products Containing the Simulated Seafood Composition
[0074] The simulated seafood composition may be combined with
additional ingredients to make a variety of seasoned seafood
products. As an example, a tuna salad product may be produced
according to the following formula:
TABLE-US-00002 TUNA SALAD Structured plant protein product 10-43%
Steamed tuna 0-33% Mayonnaise 43% Onions, chopped 7% Water
chestnuts, chopped 7% Calcium carbonate Vitamin E Omega-3 fatty
acid 0-2% Total 100%
[0075] A curry flavored tuna product may be produced using the
following formula:
TABLE-US-00003 CURRY FLAVORED TUNA PRODUCT Structured plant protein
product 15-30% Steamed tuna 35-50% Onions, chopped 5% Curry sauce
30% Vitamin A Vitamin C Omega-3 fatty acid 0-2% Total 100%
Definitions
[0076] The term "extrudate" as used herein refers to the product of
extrusion. In this context, the structured plant protein products
comprising protein fibers that are substantially aligned may be
extrudates in some embodiments.
[0077] The term "fiber" as used herein refers to a structured plant
protein product having a size of approximately 4 centimeters in
length and 0.2 centimeters in width after the shred
characterization test detailed in Example 4 is performed. Fibers
generally form Group 1 in the shred characterization test. In this
context, the term "fiber" does not include the nutrient class of
fibers, such as soybean cotyledon fibers, and also does not refer
to the structural formation of substantially aligned protein fibers
comprising the plant protein products.
[0078] The term "fish meat" as used herein refers to the flesh,
whole meat muscle, or parts thereof derived from a fish.
[0079] The term "gluten" as used herein refers to a protein
fraction in cereal grain flour, such as wheat, that possesses a
high content of protein as well as unique structural and adhesive
properties.
[0080] The term "gluten free starch" as used herein refers to
modified tapioca starch. Gluten free or substantially gluten free
starches are made from wheat, corn, and tapioca based starches.
They are gluten free because they do not contain the gluten from
wheat, oats, rye or barley.
[0081] The term "large piece" as used herein is the manner in which
a plant protein product's shred percentage is characterized. The
determination of shred characterization is detailed in Example
4.
[0082] The term "protein fiber" as used herein refers the
individual continuous filaments or discrete elongated pieces of
varying lengths that together define the structure of the
structured plant protein products of the invention. Additionally,
because the structured plant protein products of the invention have
protein fibers that are substantially aligned, the arrangement of
the protein fibers impart the texture of whole meat muscle to the
structured plant protein products.
[0083] The term "seafood meat" as used herein refers to the flesh,
whole meat muscle, or parts thereof derived from seafood.
[0084] The term "simulated" as used herein refers to a seafood
composition that contains a structured plant protein product, fatty
acid, and less than 100% seafood meat.
[0085] The term "soy cotyledon fiber" as used herein refers to the
fibrous portion of soy cotyledons containing at least about 70%
fiber (e.g., polysaccharide). Soy cotyledon fiber typically
contains some minor amounts of soy protein, but may also be 100%
fiber. Soy cotyledon fiber, as used herein, does not refer to, or
include, soy hull fiber. Generally, soy cotyledon fiber is formed
from soybeans by removing the hull and germ of the soybean from the
cotyledon, flaking or grinding the cotyledon and removing oil from
the flaked or ground cotyledon, and separating the soy cotyledon
fiber from the soy material and carbohydrates of the cotyledon.
[0086] The term "soy protein concentrate" as used herein is a soy
material having a protein content of from about 65% to less than
about 90% soy protein on a moisture-free basis. Soy protein
concentrate also contains soy cotyledon fiber, typically from about
3.5% up to about 20% soy cotyledon fiber by weight on a
moisture-free basis. A soy protein concentrate is formed from
soybeans by removing the hull and germ of the soybean from the
cotyledon, flaking or grinding the cotyledon and removing oil from
the flaked or ground cotyledon, and separating the soy protein and
soy cotyledon fiber from the carbohydrates of the cotyledon.
[0087] The term "soy flour" as used herein, refers to a comminuted
form of defatted soybean material, preferably containing less than
about 1% oil, formed of particles having a size such that the
particles can pass through a No. 100 mesh (U.S. Standard) screen.
The soy cake, chips, flakes, meal, or mixture of the materials are
comminuted into a soy flour using conventional soy grinding
processes. Soy flour has a soy protein content of about 49% to
about 65% on a moisture free basis. Preferably the flour is very
finely ground, most preferably so that less than about 1% of the
flour is retained on a 300 mesh (U.S. Standard) screen.
[0088] The term "soy protein isolate" as used herein is a soy
material having a protein content of at least about 90% soy protein
on a moisture free basis. A soy protein isolate is formed from
soybeans by removing the hull and germ of the soybean from the
cotyledon, flaking or grinding the cotyledon and removing oil from
the flaked or ground cotyledon, separating the soy protein and
carbohydrates of the cotyledon from the cotyledon fiber, and
subsequently separating the soy protein from the carbohydrates.
[0089] The term "strand" as used herein refers to a plant protein
product having a size of approximately 2.5 to about 4 centimeters
in length and greater than approximately 0.2 centimeter in width
after the shred characterization test detailed in Example 4 is
performed. Strands generally form Group 2 in the shred
characterization test.
[0090] The term "starch" as used herein refers to starches derived
from any native source. Typically sources for starch are cereals,
tubers, roots, legumes, and fruits.
[0091] The term "wheat flour" as used herein refers to flour
obtained from the milling of wheat. Generally speaking, the
particle size of wheat flour is from about 14 .mu.m to about 120
.mu.m.
EXAMPLES
[0092] Examples 1-5 illustrate various embodiments of the
invention.
Example 1
Naturally Coloring Structured Protein Product with Omega-3 Fatty
Acid
[0093] A preparation of color from fermented red rice, i.e., rice
cultured with the red mold Monascus purpureus, can be used to color
a structured protein product of the invention to resemble tuna
meat. The monascus colorant (AVO-Werke August Beisse, Belm,
Germany) will be dispersed in water and mixed with structured
soy/wheat protein product (e.g., SUPRO.RTM.MAX 5050, Solae, St.
Louis, Mo.). After 1 hour, the colored structured soy/wheat protein
product will be flaked using a Comitrol.RTM. Processor (Urschel
Laboratories, Inc., Valparaiso, Ind.).
TABLE-US-00004 TABLE 1 Formula to color the structured plant
protein product Amount SUPRO .RTM. MAX 5050 1000 g Water 2500 g
Monascus colorant 50 g Total 3550 g
[0094] Yellowfin tuna loin will be steam cooked to an internal
temperature of 60.degree. C., chilled and flaked. The cooked tuna
and the colored structured protein product will be blended in a 3:1
ratio and packed into cans, as shown in Table 2. The cans will be
retorted at 117.degree. C. for 75 minutes in a retort cooker. The
taste, color, appearance, smell, and texture of each preparation
will be evaluated.
TABLE-US-00005 TABLE 2 Contents of cans Sample Control Test Cooked
tuna, flaked 100 g 75 g Naturally colored structured protein
product 0 25 g Vegetable broth 69 g 69 g Omega-3 fatty acid 0.2 g
0.2 g Salt 0.8 g 0.8 g Total 170 g 170 g
Example 2
Artificially Coloring Structured Protein Product with Omega-3 Fatty
Acid
[0095] FD&C Red Color No. 40 and FD&C Yellow Color No. 5
can be used to color a structured protein product of the invention
to resemble tuna meat. Structured soy/wheat protein product (e.g.,
SUPRO.RTM.MAX 5050, Solae, St. Louis, Mo.) will be mixed with the
dyes as detailed in Table 3. After 1 hour, the colored structured
soy/wheat protein product will be flaked using a Comitrol.RTM.
Processor (Urschel Laboratories, Inc., Valparaiso, Ind.).
TABLE-US-00006 TABLE 3 Formula to color structured plant protein
product Amount SUPRO .RTM. MAX 5050 200 g Water 500 g Red color No.
40, 0.05% solution 40 g Yellow color, No. 5, 0.02% solution 8 g
Total 748 g
[0096] Tuna will be cooked and flaked essentially as described in
Example 1. The ingredients will be packed into cans using the
amounts listed in Table 4. The cans will be retorted at 117.degree.
C. for 75 minutes in a retort cooker. The taste, color, appearance,
smell, and texture of each preparation will be evaluated.
TABLE-US-00007 TABLE 4 Contents of cans Sample Control Test Cooked
tuna, flaked 100 g 75 g Artificially colored structured protein 0
25 g product Vegetable broth 69 g 69 g Omega-3 fatty acid 0.2 g 0.2
g Salt 0.8 g 0.8 g Total 170 g 170 g
Example 3
Determination of Shear Strength
[0097] Shear strength of a sample is measured in grams and may be
determined by the following procedure. Weigh a sample of the
colored structured plant protein product and place it in a heat
sealable pouch and hydrate the sample with approximately three
times the sample weight of room temperature tap water. Evacuate the
pouch to a pressure of about 0.01 Bar and seal the pouch. Permit
the sample to hydrate for about 12 to about 24 hours. Remove the
hydrated sample and place it on the texture analyzer base plate
oriented so that a knife from the texture analyzer will cut through
the diameter of the sample. Further, the sample should be oriented
under the texture analyzer knife such that the knife cuts
perpendicular to the long axis of the textured piece. A suitable
knife used to cut the extrudate is a model TA-45, incisor blade
manufactured by Texture Technologies (USA). A suitable texture
analyzer to perform this test is a model TA, TXT2 manufactured by
Stable Micro Systems Ltd. (England) equipped with a 25, 50, or 100
kilogram load. Within the context of this test, shear strength is
the maximum force in grams needed to puncture through the
sample.
Example 4
Determination of Shred Characterization
[0098] A procedure for determining shred characterization may be
performed as follows. Weigh about 150 grams of a structured plant
protein product using whole pieces only. Place the sample into a
heat-sealable plastic bag and add about 450 grams of water at
25.degree. C. Vacuum seal the bag at about 150 mm Hg and allow the
contents to hydrate for about 60 minutes. Place the hydrated sample
in the bowl of a Kitchen Aid mixer model KM14G0 equipped with a
single blade paddle and mix the contents at 130 rpm for two
minutes. Scrape the paddle and the sides of the bowl, returning the
scrapings to the bottom of the bowl. Repeat the mixing and scraping
two times. Remove .about.200 g of the mixture from the bowl.
Separate the .about.200 g of mixture into one of two groups. Group
1 is the portion of the sample having fibers at least 4 centimeters
in length and at least 0.2 centimeters wide. Group 2 is the portion
of the sample having strands between 2.5 cm and 4.0 cm long, and
which are .gtoreq.0.2 cm wide. Weigh each group, and record the
weight. Add the weight of each group together, and divide by the
starting weight (e.g. .about.200 g). This determines the percentage
of large pieces in the sample. If the resulting value is below 15%,
or above 20%, the test is complete. If the value is between 15% and
20%, then weigh out another .about.200 g from the bowl, separate
the mixture into groups one and two, and perform the calculations
again.
Example 5
Production of Structured Plant Protein Products
[0099] The following extrusion process may be used to prepare the
structured plant protein products of the invention, such as the soy
structured plant protein products utilized in Examples 1 and 2.
Added to a dry blend mixing tank are the following: 1000 kilograms
(kg) Supro 620 (soy isolate), 440 kg wheat gluten, 171 kg wheat
starch, 34 kg soy cotyledon fiber, 9 kg dicalcium phosphate, and 1
kg L-cysteine. The contents are mixed to form a dry blended soy
protein mixture. The dry blend is then transferred to a hopper from
which the dry blend is introduced into a preconditioner along with
480 kg of water to form a conditioned soy protein pre-mixture. The
conditioned soy protein pre-mixture is then fed to a twin-screw
extrusion apparatus (Wenger Model TX-168 extruder by Wenger
Manufacturing Inc. (Sabetha, Kans.)) at a rate of not more than 25
kg/minute. The extrusion apparatus comprises five temperature
control zones, with the protein mixture being controlled to a
temperature of from about 25.degree. C. in the first zone, about
50.degree. C. in the second zone, about 95.degree. C. in the third
zone, about 130.degree. C. in the fourth zone, and about
150.degree. C. in the fifth zone. The extrusion mass is subjected
to a pressure of at least about 400 psig in the first zone up to
about 1500 psig in the fifth zone. Water, 60 kg, is injected into
the extruder barrel, via one or more injection jets in
communication with a heating zone. The molten extruder mass exits
the extruder barrel through a die assembly consisting of a die and
a backplate. As the mass flows through the die assembly the protein
fibers contained within are substantially aligned with one another
forming a fibrous extrudate. As the fibrous extrudate exits the die
assembly, it is cut with flexible knives and the cut mass is then
dried to a moisture content of about 10% by weight.
* * * * *